Convection cooled mattress

ABSTRACT

An orthopedic mattress that provides cooling as well as comfort to a user. The mattress includes a convoluted top surface having a plurality of air vents, and sidewalls having a set of air channels that communicates with the air vents to promote the circulation of air throughout the mattress.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to an orthopedic mattress and, in particular, an air mattress that includes a series of air vents and air channels that promote the cooling of the mattress by natural convection.

2. Related Art

Today millions of people suffer from back and back induced pain and discomfort.

In many cases these problems can be traced back to poor sleeping habits and even poorer quality beds and mattresses. Also, patients and other persons confined to a bed for long periods of time frequently develop pressure sores, which are medically known as decubitus ulcers and which are commonly referred to as bedsores. Decubitus ulcers are formed due to an interruption of blood flow in the capillaries below skin tissue due to pressure against the skin. These pressure sores can be debilitating and painful and, in extreme cases, can lead to death.

In many instances an orthopedic mattress may be utilized to ease, or even alleviate the foregoing problems. An orthopedic mattress is useful because it promotes a healthy back and alleviates bed pain by supporting the spine in its correct alignment and by avoiding the development of localized pressure points. This in turn makes an orthopedic mattress comfortable, restful, and supportive and people who use orthopedic beds tend to sleep better, feel more rested in the morning, and are less likely to become restless during the night.

Orthopedic mattresses come in a range of constructions from traditional springs and coils, to memory foam, latex foam, and composites of all three compositions. In particular, memory foam and latex mattresses are typically made to conform to the user's body rather than be hard or very firm. In this way, a mattress that contours around the sleeper enables the mattress to fill the gap under the lower back, while still being firm and offering support to the rest of the body without sagging or deflecting.

Memory foam is a polyurethane-based foam that reacts to pressure and body heat. These properties allow the foam to mold itself to the shape of a warm body within a few minutes. By its nature, memory foam holds a lot of heat because the foam would not be effective if it didn't dissipate heat so slowly. Thus, an orthopedic mattress using memory foam may sleep warmer than traditional mattresses, especially in warm climates, which may make the user hot and sweaty. Thus, a need exists for an orthopedic mattress that provides cooling as well as comfort to the user.

SUMMARY

An air mattress is provided for use in orthopedic bedding. The mattress includes a convoluted top surface having a plurality of air vents, and sidewalls having a set of air channels that communicates with the air vents to promote the circulation of air throughout the mattress. In use, air is drawn into the set of air channels and ejected through the air vents to cool a user by natural convection.

Also provided is a method of cooling a mattress. The method includes the steps of forming at least one air vent through a top surface of the mattress; forming at least one air channel in at least one sidewall of the mattress, wherein at least one air channel communicates vent with at least one air vent formed in the top surface; drawing cool air into at least one air channel of the mattress, the cool air passing from at least one air channel to at least one air vent fanned in the top surface; and ejecting the cool air from the mattress through at least one air vent. At least one elongated air channel may be formed in at least one sidewall of the mattress to provide more convection cooling in some areas of the mattress over other areas of the mattress.

Other devices, apparatus, systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE FIGURES

The invention may be better understood by referring to the following figures. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the figures, like reference numerals designate corresponding parts throughout the different views.

FIG. 1 is a perspective view of one example of one implementation of an air mattress of the present invention.

FIG. 2A is a top view of the air mattress of FIG. 1.

FIG. 2B is a cross sectional view of the air mattress of FIG. 1.

FIG. 3 is a side view of the air mattress of FIG. 1.

FIG. 4 is a partial side perspective view of the air mattress of FIG. 1 illustrating the passage of air through the air channels of the mattress.

FIG. 5 is a perspective view of a second example of one implementation of an air mattress of the present invention.

DETAILED DESCRIPTION

FIG. 1 illustrates one implementation of an embodiment of a mattress 20 of the present invention. As illustrated, the mattress 20 includes a support layer 30, a base layer 40, and a convection layer 50 disposed between the support layer 30 and the base layer 40.

According to the invention, the mattress 20 and each of its layers are formed of a foam material. For example, the mattress 20 may be formed of a memory foam, latex rubber foam, rebond foam, polyurethane foam, high density foam, evlon foam, high resilience foam, closed cell foam, open cell foam, or any other suitable foam material. The mattress 20 may be constructed to a rectangular shape or any other suitable construction. The mattress 20 may also be constructed to a thickness ranging from approximately 8 inches to 16 inches, and to the dimensions of conventional bedding including hospital, twin, full, queen, king, California king, California queen, and super king-sized bedding.

The support, convection, and base layers 30, 50, and 40 may be formed from a single piece of foam or integrally formed or molded with one another as three discrete layers. The support, convection, and base layers 30, 50, and 40 may be of the same resilience, or the support layer 30 may be of greater resilience (i.e., made from a lighter density foam) than the convection and base layers 50, 40 to provide softness to the user. For example, in one implementation the support layer may have a 4 lb density, the convection layer may have a 2 lb density, and the base layer may have a 2 lb density. Similarly, the mattress 20 layers may be constructed from the same type of foam material or alternatively, each layer may be constructed from a different type of foam.

Turning to FIGS. 2B, and 3, the support layer 30 includes a convoluted top surface 32 having a plurality of air vents 34 (see also FIG. 2A), and a planar bottom surface 36. In one implementation (shown in FIGS. 2A, 2B, and 3), the top surface 32 of the support layer 30 is corrugated, but in other implementations the top surface 32 may include an eggcrate, pane, checkerboard, sawtooth, or other suitable design. The support layer 30 is configured to provide lumbar spine support and an even distribution of body weight to minimize the pressure applied against the user lying on the mattress 20.

The air vents 34, as shown in the figures, are holes that extend from the top surface 32 to the bottom surface 36 of the support layer 30. The air vents 34 are configured to allow cool air drawn into the mattress 20 to flow out of the support layer 30, The air vents 34 may be uniformly distributed throughout the support layer 30 to provide uniform cooling, while increasing the ability of support layer 30 to conform to the user's body. In one implementation, the air vents 34 may be 0.25 inch drill holes, but in other implementations the air vents 34 may be constructed of any suitable size or shape.

Referring now to FIG. 3, the base layer 40 may be a solid a piece of foam. The base layer 40 supports the mattress 20 and is configured to rest on the box spring of a bed. As the base of the mattress, the thickness of the base layer 40 may be greater than the thickness of the support and convection layers 30, 50. For example, in one implementation, the base layer 40 may have a thickness of 7 inches, while the convection layer 50 may have a thickness of 4 inches and the support layer 30 may have a thickness of 3 inches. However, the thickness of the base layer 40 may vary according to the desired stiffness and rigidity of the mattress 20.

Referring now to FIGS. 2B and 3, the convection layer 50 includes a planar top surface 52, axial sidewalls 54, and a planar bottom surface 56. The sidewalls 54 include a first set of transverse notches 60 formed along the top surface 52 of the convection layer 50, and a second set of transverse notches 62 formed along the bottom surface 56 of the convection layer 50. In one implementation, the transverse notches 60, 62 extend from one sidewall to an opposite sidewall.

In one implementation, the first set of notches 60 and the bottom surface 36 of the support layer 30 define a first set of air channels 64. These air channels 64 are configured to communicate with the air vents 34 formed in the support layer 30 to promote the circulation of air throughout the mattress 20. The second set of notches 62 and a top surface of base layer 40 define a second set of air channels 66. These air channels are configured to draw-in cool air on one side of the mattress 20, and displace warm air on an opposite side of the mattress 20. In one implementation, the air channels 64, 66 may have dimensions of 1 inch by 0.75 inches, but the air channels may be constructed to any suitable dimensions. In one implementation, shown in FIGS. 2B and 3, the air channels may be irregular in shape, but in other implementations the air channels may be constructed of different geometries. For example, the air channels may be rectangular, circular, triangular, or any other suitable shape.

In use, the mattress 20 is positioned on the box spring of a bed with the support layer 30 uppermost, as shown in FIG. 1. When a user rests on the support layer 30 of the mattress 20, the support layer 30 tends to deform to closely conform to the contour of the user's body to gently support and evenly distribute the weight of the user over the surface area of the top surface 32. As the user rests on the support layer 30 of the mattress 20, the user's body generates heat that is absorbed by the mattress 20. As illustrated in FIG. 4, cool air (depicted by arrows 70 and 72) is drawn into the air channels 64, 66 in the convection layer 50 by natural convection. Air 70 passing through the first set of air channels 62 communicates with air vents 34 in the support layer 30 to eject cool air from the support layer 30 to cool the user. Air 72 passing through the second set of air channels 66 displaces from the convection layer 50 warm air generated by the user's body heat, as depicted by arrow 74. Thus, the convection layer 50 acts as a heat exchanger, as the circulation of air throughout the mattress provides the advantage of enabling the mattress to be cooled during its use, by natural convection.

As better shown in FIG. 2B, in one implementation, one or more air channels 64, 66 may be elongated in certain areas of the mattress where the user's body generates more heat (“hot zones”). The elongated air channels allow more air flow in these areas to provide more convection cooling to these hot zones. However, in other implementations, the air channels may be uniform to provide uniform cooling along the mattress.

In use, the mattress 20 may be enclosed by a mattress cover (not shown) for durability and sanitary purposes.

FIG. 5 illustrates another implementation of the mattress 20 of the present invention. In this example, a third and fourth set of air channels 130, 140 may be formed in transverse sidewalls 110 of the convection layer 50. In this configuration, the third and fourth set of air channels 130, 140 intersect the first and second set of air channels 64, 66, respectively. Similar to the first and second set of air channels 64, 66, the third set of air channels 130 may be configured to communicate with the air vents 34 formed in the support layer 30 to promote the circulation of air throughout the mattress 20, and the fourth set of air channels 140 may draw in cool air on one side of the mattress 20 and displaces warm air on an opposite side of the mattress.

The foregoing description of implementations has been presented for purposes of illustration and description. It is not exhaustive and does not limit the claimed inventions to the precise form disclosed. Modifications and variations are possible in light of the above description or may be acquired from practicing the invention. The claims and their equivalents define the scope of the invention. 

1. A mattress comprising: a top surface having at least one air vent; and sidewalls having at least one air channel spaced apart from the top surface that communicates with the at least one air vent to promote the circulation of air throughout the mattress.
 2. The mattress of claim 1 wherein the top surface is convoluted.
 3. The mattress of claim 1 wherein the sidewalls include a first plurality of air channels, the first plurality of air channels extending from one sidewall to an opposite sidewall.
 4. The mattress of claim 3 wherein the top surface includes a plurality of air vents, the air vents vertically extending from the top surface to the first plurality of air channels.
 5. The mattress of claim 4 further including a second plurality of air channels extending from one sidewall to an opposite sidewall, the second plurality of air channels being spaced apart from the first plurality of air channels.
 6. The mattress of claim 5 wherein the second plurality of air channels includes one or more elongated air channels for providing more convection cooling in some areas of the mattress over other areas of the mattress.
 7. A mattress comprising: a support layer having a top surface and at least one air vent vertically extending therethrough; and a convection layer integral to the support layer and the base layer, wherein the convection layer includes a sidewall and at least one air channel extending from the sidewall that intersects with the at least one air vent to promote the circulation of air throughout the mattress.
 8. The mattress of claim 7 further comprising a base layer integral to the support layer wherein the convection layer is disposed between the support layer and the base layer.
 9. The mattress of claim 7 wherein the top surface is convoluted.
 10. The mattress of claim 7 wherein the convection layer includes sidewalls and a first plurality of air channels, the air channels extending from one sidewall to an opposite sidewall.
 11. The mattress of claim 10 wherein the top surface includes a plurality of air vents, the air vents vertically extending from the top surface to the first plurality of air channels.
 12. The mattress of claim 11 wherein the convection layer further includes a second plurality of air channels extending from one sidewall to an opposite sidewall, the second plurality of air channels being spaced apart from the first plurality of air channels.
 13. The mattress of claim 12 wherein the second plurality of air channels includes one or more elongated air channels for providing more convection cooling in some areas of the mattress over other areas of the mattress.
 14. The mattress of claim 8 wherein the support layer, the convection layer, and the base layer are integrally molded with one another as three discrete layers.
 15. A method for cooling a mattress, the method including the steps of: forming at least one air vent through a top surface of the mattress; forming at least one air channel in at least one sidewall of the mattress, wherein at least one air channel is spaced apart from the top surface and intersects with the at least one air vent formed in the top surface; drawing cool air into at least one air channel of the mattress, the cool air passing from at least one air channel to at least one air vent formed in the top surface; and ejecting the cool air from the mattress through at least one air vent.
 16. The method of claim 15 wherein a first plurality of air channels are formed in at least one sidewall of the mattress.
 17. The method of claim 16 wherein a plurality of air channels vents are formed though the top surface of the mattress, the plurality of air vents vertically extending from the top surface to the first plurality of air channels.
 18. The method of claim 17 further including the step of forming a second plurality of air channels in at least one sidewall of the mattress, the second plurality of air channels being spaced apart from the first plurality of air channels.
 19. The mattress of claim 18 further including the step of forming at least one elongated air channel in at least one sidewall of the mattress to provide more convection cooling in some areas of the mattress over other areas of the mattress.
 20. The method of claim 15 further including the step of convoluting the top surface of the mattress. 